In recent years, China Gezhouba Cement Company has taken the three-year action of state-owned enterprise reform as its main focus, accelerated the implementation of the strategy of "strengthening enterprises by science and technology, innovating and developing", accelerated the pace of deep integration of digital technology and production and operation, gradually promoted the intelligent transformation and upgrading of cement production from manufacturing to "intelligent manufacturing", and helped enterprises achieve green and low-carbon development.
Strengthen top-level design, promote management and upgrade
the company to compile and issue the "14th Five-Year Plan for the Development of Science and Technology and Informatization", and clearly put forward six key tasks, such as building a cement intelligent factory and a "1 + 6 + 1" integrated platform for informatization. To achieve digital transformation and deep integration of "two modernizations", so as to further enhance the level of intelligent manufacturing.
Taking the construction of adaptive organization as an opportunity, the system integrates the functions of technology management, scientific and technological research and development and information management, optimizes and improves the scientific and technological committee as the decision support body, the technical specialist committee as the major technical support body, the green building materials engineering and technology research center as the technology research and development department, and the technical specialist as the technology. It covers the science and technology and information management structure of the management departments and research branches of the affiliated units, and coordinates the construction of digitalization and intellectualization of the company.
Relying on the technical specialist team, based on the production line, through remote diagnosis, stationary services and other ways to coordinate the promotion of related work, strengthen the in-depth training of technical personnel.
Strengthen intelligent production, promote production digitalization
in mining, raw material proportioning, cement grinding and other production links, through the application of neutron on-line analyzer, on-line laser particle size analyzer, automatic sampling and sampling device for raw and fuel materials into the plant and other on-line detection equipment. Real-time monitoring of raw materials and product quality and automatic sampling and sample preparation are realized, the frequency of manual inspection is greatly reduced, the comprehensive qualified rate of raw materials from grinding is further improved, and the strength stability of clinker is greatly improved.
Establish equipment on-line monitoring and fault diagnosis system, use intelligent patrol inspection, on-line monitoring, production DCS and other data to achieve all-round monitoring of equipment status, closed-loop management of equipment installation, commissioning, operation, maintenanc e and other life cycle, to achieve equipment predictive maintenance or condition-based maintenance, and to achieve equipment maintenance. To ensure the safe, stable, efficient and long-term healthy operation of the equipment. After the application of the system, the accuracy rate of fault diagnosis is 83. 3%, and the rate of point inspection is 93%. The unmanned intelligent driving system of the joint depot, which integrates the remote control center, the ground system and the on-board system, is
constructed to change the traditional manual driving mode, realize the unmanned driving of the intelligent driving system of the joint depot and reduce the labor intensity. At the same time, the integrated application of automatic bag insertion machine, bagged cement automatic loading machine, intelligent logistics system, etc., replaces the manual bag insertion and loading of cement. The success rate of bag insertion is stable at about 99%, and the working efficiency of automatic loading machine is 90 ~ 110 t/H, which realizes the unattended logistics in the factory and improves the efficiency of logistics transportation.
Strengthen centralized management and control, promote management informatization
, automatically collect production data and energy consumption data of nearly 100000 points in cement production line of affiliated units by building production and operation management platform, and realize real-time monitoring of production DCS, abnormal alarm and real-time display of production and operation data. The platform integrates sales ERP and other business systems, establishes a data interaction and sharing mechanism, quickly, comprehensively and timely grasps the relevant information of production, supply, sales, storage and energy consumption in a visual way, eliminates information blind spots, information lag and repeated data submission from top to bottom, and provides support for production and operation decision-making. With the production and operation management platform as the technical support, in 2021, the comprehensive power consumption of clinker decreased by 1.06 kWh/ton, the power consumption of cement decreased by 0.4 kWh/ton, the standard coal consumption of clinker decreased by 2.55 kg/ton, the total annual power savings of 10 kiln line enterprises and 2 cement grinding enterprises were about 32 million degrees, and the standard coal was about 53000 tons. The total value is nearly 80 million yuan.
Establish a production command center integrating monitoring center, production scheduling center and energy management display center. The production system and production site of the subsidiary company are monitored online for 24 hours, and the production scheduling video intercom system is used to realize online analysis, remote diagnosis and emergency command, so that the production management mode is changed from traditional on-site management to remote collaborative management. In 2021, the temporary shutdown rate of rotary kiln failure decreased by 44.91% (absolute value decreased by 0.75%) compared with 2019, and the temporary shutdown rate of cement mill failure decreased by 38.46% (absolute value decreased by 0.5%) compared with 2019, which significantly reduced the failure rate of main equipment and ensured the stable and efficient operation of production management system.
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